Radiation thermocouple



April 13, 1954 W A RAY RADIATION THERMOCOUPLE Filed Aug. 19, 1949 7 0 e L m M E R w p A H O U C C Q Gttorneg Patented Apr. 13, 1954 RADIATION 'THERMOCOUPLE William A. Ray, North Hollywood, Calif., assignor yto General Controls Co., Glendale, Calif., a corporation of California Application August 19, 1949, Serial'No. 111,197

4 Claims.

My present 'invention relates to thermoelectric generating devices; a main object of the invention being to provide a thermocouple ystructure adapted to be subjected directly to a ame and yet capable of responding very rapidly to the establishment and -extinguishment of the ame.

The importance of high-speed operation of name-responsive safety devices is now well recognized, especially in industry, and systems'of the flame-conduction type, which depend on conduction of electricity Iby the ions of a ame, are employed in order to achieve the desired rapidity of response. However, such systems are not entirely satisfactory -due to: (-1) the fact that fluttering of the flame may cause 'false operation because of the ultra-'rapid response 0f the system, so that time-delay means must be provided, (2) eventual deterioration'of the electrodes subjected to the flame. which may result lin erratic or unsafe operation, and (3') the fact that the current conducted through the ame `is usually supplied from the A. C. service lines so that variation 0f the line vvoltage,'when amplified in thev system, may effect false operation.

B y the use of ,a thermocouple structure according to the present invention a `system can be provided which is free from the disadvantages, pointed out in the preceding paragraph, of a flame-conduction system and `yet has suiciently rapid response to meet most requirements.

The advantages of `a flame-responsive control system according to this invention are inherent in the thermocouple structure-(1l) whose operative response to .flame failure is rapid (down to 1-2 seconds), but not so rapid as to necessitate use of time-delay means, l(2') which is .not subject .to deterioration by long exposure to the name, and (3) which ,generates its own source of steady D. C. so that the .controlling energy is independent of conventional electric sources.

`In my Patent No. '2,466,274 ,a thermocoupleis described and claimed whose rapidity of response depends on `the fact that its hot and 4Vits cold junction are close to each other and are exposed substantially equally to a ,ame or to the hot gases in a furnace; the .required diierence of temperature at the junctions being due mainly to the difference of 'mass of Vthe thermocouple elements at and Vadjacent the Vjunctions whereby the cold junction has a greater cooling effect on the hot gases than does the hot junction and therefore Vremains 'at a lower temperature.

The thermocouple of the present invention, while also having a similar arrangement #of adjacent hot and cold junctions. diiers from' r`the thermocouple of lsaid patent inthat the elements of the thermocoup'le of this invention are arranged to be subjected substantially solely to thermal radiation. Thermal radiation can be appreciated only 'when absorbed by a vbody and then converted by it linto heat. A Ybody obviously cannot have a cooling effect on Vthermal radiation, as does a body yupon larne or other hot gases to which it is exposed. Furthenin a radiation thermocouple but littlevradiation can be absorbed by the junctions themselves, so 'that the temperature at the junctions depends `mainly upon vthe heat conducted to them `by the `adjoining portions of the elements, vthe amount of which heat is determined by the `radiation-absorbing area of those portions. In distinction, when the junctions of a therm'ocouple are in a flame or other hot gases, heat is conducted from the gases vdirectly to the junctions jthemselves, and the Vthermoelectric Veffectis in no way influenced by the temperature of the portions of the elements between the junctions.

The teaching heretofore has been that a thermocouple of the Aradiation type must be remote from the source of heat. In distinction, I encase the thermocouple in an evacuated envelope of material such as quartz and subject the envelope directly to the flame. By lthis arrangement, radiation losses are minimized, and deterioration of the materials of the thermocouple is substantially eliminated, so that the materials can be selected from those having high thermoelectric powers but incapable of withstanding prolonged exposure to heated gases.

For full understanding of the invention, and further appreciation of its `objects and advantages, reference is to be had to the following detailed description and accompanying drawing, and -to the appended claims.

In the drawing.:

-Figure 1 is a longitudinal sectional view of a thermocouple structure embodying this invention, taken generally along the lines l--l .of Fig. '2;

Figure 2 is a transverse section taken along the line'2--2 of Fig. l; and

Figure 3 is a view in perspective, and to enlarged scale, ,of a part employed in the construction of the thermocouple shown in the .other gures.

Referring now more particularly to the drawing, the numeral -Il indicates a tubular envelope which, after evacuation, is sealed-01T vat its `bottom as indicated at l2. The envelope H is of material having vgood 'transmittancy of thermal radiation, such as quartz glass. Around the lower part of the envelope is a protective metal sleeve I 3 which serves as means for mounting the thermocouple structure in a suitable fixture.

Within the upper part of the envelope is a thermocouple which comprises three seriallyjoined electric conductors: a long rod or Wire I4 forming one end conductor, a short rod or wire I 5 forming an intermediate conductor, and a thin sheet-metal conductor I6 forming the other end conductor. In the preferred embodiment of the invention as shown there are three of the conductors I5, indicated at I6, I6 and (seen only in Fig. 2) I6", each of inverted Lshape and joined at the ends of their short horizontal portions to the upper portion of the intermediate conductor or rod I5. For connecting the thermocouple to an external load, a wire I 'I is welded to the bottom of conductor I6, this wire extending downwardly and being welded to a conventional terminal wire I8 which sealingly projects through the bottom wall of the envelope. The end conductor or wire I 4 is joined directly to a similar terminal wire I9.

To reduce the electrical resistance of the therrnoccuple the sheet-metal conductors i6 and I5" are preferably connected in parallel with conductor E6; conductor I6' being shown so connected by a wire welded to wire I1 at 20', but to avoid possible confusion no such wire is shown connecting conductor I5 since that conductor cannot be seen in Fig. 1.

The conductors I6, I5' and I6" are constructed from three inverted U-shaped pieces (one of which is shown per se in Fig. 3) whose side arms are at an angle of 120 as viewed from the top, the central part of the cross-arm of the U being curved as indicated at 2I to conform to a segment 0f the circumference of rod I5. The three pieces, each as shown in Fig. 3, are joined together, as by projection welding, to form the three-pointed assembly seen in Fig. 2, and then are welded by their portions 2I to the rod I5. -The lower point of Contact 22 between rod I5 and conductors I5, i6 and IE" forms one thermoelectric junction of the thermocouple, the other thermoelectric junction being at the weld 23 between rods I5 and I 4. The sheet metal of which conductors I6, I6' and I6" are constructed is very thin; it being in a practical embodiment 0.002 inch thick so that the total thickness of each finished conductor was 0.004 inch. In the same embodiment the diameter of rods I4 and I5 (and of wires I1 and 20) was about 0.045 inch.

To support the thermocouple at its lower end there is a ceramic disk 24, closely fitting within the envelope, having openings for the wires or rods i4, I'! and 20. To maintain the conductors I5, I6 and IS" in substantially spaced relation to the wall of the envelope and thereby minimize transfer of heat therebetween, these conductors are provided with triangular projections 25 which can make only point-contact with the envelope.

In use, the upper part of the envelope is subjected directly to a flame 25 shown issuing from a vertical slot in a gas burner 21. By reason of the three-pointed or angular arrangement of the conductors I5, I8 and I5 (see Fig. 2), substantially the same surface area of these conductors is presented toward all sides of the envelope, so that no particular orientation of the structure in relation to the fiame is necessary.

The intermediate conductor I5 is conveniently of an alloy containing approximately 90% Ni and 10% Cr (such as Chromel), and all of the other conductors i 4, I 6, I5 and I6" (as well as the extensions I'I and 20) of an alloy containing approximately 55% Cu and 45% Ni (such as Copel) the wires I8 and I9 being of the usual material suitable for sealing to quartz glass. While the particular alloys mentioned are those at present preferred, other materials may be substituted; the only requirement being that the intermediate conductor I5 be of material thermoelectrically dissimilar to those'of the end conductors I4 and I6.

When the structure is subjected to a flame as shown in the drawing, a relatively large proportion of the thermal radiation produced by the flame is transmitted by the quartz envelope to the elements or conductors of the thermocouple. This radiation is absorbed by the conductors and converted into heat which passes to the thermoelectric junctions 22 and 23. Inasmuch as the area of the surfaces of the sheet-metal conductors I6, I 6' and I5" exposed to the radiation is large in relation to that of the corresponding surfaces of the rodelike conductors I5 and I4, the amount of heat passing from the sheet-metal conductors and conductor l5 to the upper junotion 22 is greater than that passing from conductors I5 and I4 to the lower junction 23 so that the temperature of junction 22 becomes higher than that of junction 23.

The difference of temperature at the junctions is constant while the flame exists since the end conductor I4 and the sheet-metal end conductors are connected to the exterior of the structure through like leads or wires I8 and I9 and the heat losses from the conductors by conduction through these leads is therefore the same. The envelope being evacuated, and the conductors all spaced from the envelope (except for possible point-contact of the projections 25), heat losses other than through the leads I8 and I3 is substantially only that due to reradiation.

The difference of temperature normally maintained at the junctions 22 and 23 is not great, but the electrical energy thereby generated is ample for control purposes, as when, for example, it is employed to saturate the reactor of a magnetic amplifier. In practical embodiments of the invention, of approximately the same size and construction as shown in the drawing, and as described, when the structure was subjected to an ordinary gas flame the total power output was of the order of 25 to 250 microwatts, which corresponds to an E. M. F. of about 1.5 to 10 millivolts when the total resistance of the thermocouple is 0.1 to 0.5 ohm.

When the ame is extinguished, equalization of the temperature of the junctions 22 and 23 occurs rapidly; the time being of the order of 1 to 5 seconds in the practical embodiments described. The rapidity of equalization of temperature (when the ame is extinguished) is due not only to the proximity of the junctions and the rapid uniform distribution of the heat stored in the portions of the conductors adjacent the junctions, but also to the large radiating surface and relatively small mass of the thin sheet-metal conductors joined to the hot junction 22, whereby the heat at that junction is quickly dissipated. A reasonably high degree of vacuum in the envelope, as well as substantial spacing of the conductors from the envelope, are essential to avoid conduction of heat to the thermocouple from the slowly-cooling envelope after the llame is extinguished, since such conduction of heat would greatly increase the time required for equalization of the temperature of the junctions.

The required dierence of temperature of the junctions is quickly reached after the llame is lighted due to the large radiation-absorbing area of the sheet-metal conductors and to the thinness of the same. It is to be observed that in the practical embodiment described the surface area of the sheet-metal conductors subjected to radiation is several times (approximately six times) that of the corresponding surface of the rod-like conductors i4 and i5, While the total crosssectional area (or mass per unit length) of the three sheet-metal conductors is only slightly in excess of the cross-sectional area of each of the conductors I4 and I5.

The specific embodiment of my invention herein shown and described is obviously susceptible of modification Without departing from the spirit of the invention, and I intend therefore to be limited only by the scope of the appended claims.

I claim as my invention:

1. A thermocouple structure comprising: a tubular envelope of material having good transmittancy of thermal radiation and adapted to be subjected directly to a ilame, said envelope being evacuated and sealed; and a thermocouple so mounted in said envelope as to minimize transfer of heat from the envelope to the thermocouple, said thermocouple comprising two end conductors and an intermediate conductor serially joined to form a pair of adjacent thermoelectric junctions, said thermoelectric junctions being so arranged that when the envelope is subjected to said flame the junctions are exposed substantially equally to thermal radiation from the flame, said intermediate conductor being of material thermoelectrically dissimilar to that of the end conductors, one of said end conductors being of thin sheet metal, the other of the conductors both being of rod-like form and thick in relation to said sheet metal, said sheet-metal conductor Ibeing elongated and arranged longitudinally of said tubular envelope, said rod-like conductors being coaligned and arranged longitudinally of the envelope in spaced and generally parallel relation to the sheet-metal conductor, the area of the surface of the sheet-metal conductor exposed to thermal radiation transmitted by the envelope being at least several times that of the corresponding surface of the intermediate and the other of the end conductors.

E. A thermocouple structure as defined in claim 1, and wherein the length of the intermediate rodlike conductor exposed to the thermal radiation is considerably less than the length of the other of the rod-like conductors so exposed.

3. A thermocouple structure comprising: a tubular envelope of material having good transmittancy of thermal radiation and adapted to be subjected directly to a ilame, said envelope being evacuated and sealed; and a thermocouple so mounted in said envelope as to minimize transfer of heat from the envelope to the thermocouple, said thermocouple comprising two end conductors and an intermediate conductor serially joined to form a pair of adjacent thermoelectric junctions, said thermoelectric junctions being so arranged that when the envelope is subjected to said flame the junctions are exposed substantially equally to thermal radiation from the ame, said intermediate conductor being of material thermoelectrically dissimilar to that of the end conductors, one of said end conductors being formed by a plurality of elongated sheet-metal elements arranged longitudinally of said tubular envelope generally parallel to each other and electrically interconnected in parallel, the intermediate conductor and the other of the end conductors both being of rodlike form and thick in relation to said sheet metal, said rod-like conductors being coaligned and arranged longitudinally of the envelope in spaced and generally parallel relation to said sheet-metal elements, the area of the surfaces of the sheetmetal elements exposed to thermal radiation transmitted by the envelope being at least several times that of the corresponding surface of the intermediate and the other of the end conductors.

4. A thermocouple structure as dened in claim 1, and wherein said sheet-metal elements are so arranged as to present substantially the same area of surface toward all sides of the tubular envelope.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,474,903 Hase Nov. 20, 1923 2,466,274 Ray Apr. 5, 1949 FOREIGN PATENTS Number Country Date 706,670 Germany May 31, 1941 OTHER REFERENCES Corning: Metals and Alloys, September 1944, page 715. 

